Engine/manual gearbox assembly - removal and separation
Note: Refer to the warning at the beginning of Section 5 before proceeding. A suitable hoist and lifting tackle will be required for this operation.
1 Proceed as described in paragraphs 1 to 21 of Section 5.
2 Unscrew the securing bolt, and disconnect the earth lead from the rear left-hand side of the cylinder head.
3 Unscrew the nuts securing the engine mountings to the engine mounting brackets.
4 Jack up the vehicle and support it securely on axle stands (see “Jacking and Vehicle Support”).
Ensure that there is enough working room beneath the vehicle.
5 To improve access, disconnect the exhaust downpipe from the manifold, and remove the exhaust system.
6 Drain the engine oil into a suitable container.
7 On models fitted with a catalytic converter, release the securing clips, and withdraw the exhaust heat shield from under the vehicle for access to the propeller shaft.
8 Remove the propeller shaft.
9 Where applicable, bend back the locktabs, then unscrew the two bolts in each case securing the two anti-roll bar U-clamps to the vehicle underbody. Lower the anti-roll bar as far as possible.
10 Working inside the vehicle, place a wooden block under the clutch pedal to raise it fully against its stop, so holding the automatic adjuster pawl clear of the toothed quadrant.
11 Disconnect the clutch cable from the clutch release arm, and pass the cable through the bellhousing.
12 Support the gearbox with a trolley jack, using a block of wood between the jack and the gearbox to spread the load.
13 Unscrew the four nuts securing the gearbox crossmember to the vehicle underbody. Unscrew the central bolt securing the crossmember to the gearbox, and remove the crossmember. Note the position of the earth strap, where applicable. Recover the mounting cup, and where applicable the exhaust mounting bracket and heat shield.
14 Lower the gearbox slightly on the jack, then remove the securing circlip, and disconnect the speedometer drive cable from the gearbox.
15 Disconnect the wiring from the reversing lamp switch. On models with fuel injection, disconnect the wiring from the vehicle speed sensor mounted in the side of the gearbox.
16 Unscrew the two securing bolts, and disconnect the gear linkage support bracket from the gearbox.
17 Using a suitable pin punch, drive out the roll-pin securing the gearchange rod to the gear linkage.
18 Attach a suitable hoist to the engine lifting brackets located at the front and rear of the cylinder head, and carefully take the weight of the engine. Arrange the lifting tackle so that the engine/gearbox assembly will assume a steep angle of approximately 40º to 45º as it is being removed.
19 To improve clearance in the engine compartment when lifting the engine, unbolt the engine mounting brackets from the cylinder block, and remove them.
20 Ensure that the steering wheel is positioned in the straight-ahead position, then remove the clamp bolt from the lower steering column clamp, swivel the plate to one side, and disconnect the lower steering column from the lower flexible coupling.
21 Detach the brake lines from the front suspension crossmember.
22 Support the crossmember with a jack (do not remove the jack from under the gearbox), then loosen the bolts securing the crossmember to the underbody. Remove the crossmember securing bolts, and carefully lower the crossmember sufficiently to allow the engine sump to clear the steering rack and crossmember as the engine/gearbox assembly is removed.
23 Make a final check to ensure that all relevant wires, pipes and hoses have been disconnected to facilitate removal of the engine/ gearbox assembly.
24 Raise the engine/gearbox, at the same time lowering the trolley jack which is supporting the gearbox.
25 Place a suitable rod across the vehicle underbody to support the gear linkage support bracket whilst the gearbox is removed.
26 Tilt the engine/gearbox assembly using the hoist and the trolley jack, until the assembly can be lifted from the vehicle. Take care not to damage surrounding components.
27 If the vehicle is to be moved while the engine/gearbox assembly is removed, temporarily refit the suspension crossmember and the anti-roll bar to the underbody, and reconnect the steering column to the intermediate shaft.
28 To separate the engine from the gearbox, proceed as follows.
29 Remove the starter motor.
30 Support the engine and gearbox horizontally on blocks of wood.
31 Unscrew the engine-to-gearbox bolts, noting the locations of the bolts, and the positions of the earth strap and any wiring clips attached to the bolts. Recover any shims fitted between the sump and the gearbox when removing the lower engine-to-gearbox bolts.
32 Unscrew the bolt from the engine adapter plate.
33 Pull the engine and gearbox apart, taking care not to strain the gearbox input shaft. It may be necessary to rock the units slightly to separate them.
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